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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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90 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Chemical heterogeneity modulated zero thermal expansion alloy over super-wide temperature range

Chemical heterogeneity is usually avoided in solution chemistry, but it may still occur with sometimes dramatic effects on target materials and their properties. Here, we propose chemical heterogeneity as a counterintuitive strategy to design high-performance zero thermal expansion (ZTE) alloys. We apply this approach in a Hf-Ti-Fe alloy with excess Fe in the Hf/Ti sublattice and produce Hf/Ti concentration alternations at the micro level. Such chemical heterogeneity regulates local magnetic interactions in alloy and triggers a dispersed magnetic phase transition that modulates the thermal expansions at the micro level and hence results in a remarkable ZTE behavior over a super-wide temperature window from 10 to 480 K. This mechanism is supported by comprehensive studies on morphological microstructures, crystal and magnetic structures, and theoretical calculations. The strategy of local chemical heterogeneity opens up an avenue to design ZTE and the related functional materials directly via microstructure engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microscale Observation via High-Speed X-ray Diffraction of Alloy 718 During In Situ Laser Melting

The laser melting process is accompanied by rapid evolution in temperature, phase, structure, and strain because of its high heating and cooling rates. In this study, the evolution of grains within a thin solid plate of Ni alloy 718 during laser processing was probed with in situ high-energy x-ray diffraction experiments. The high temporal and spatial resolution available in the measurement allowed us to study the rapid evolution of the melted region beneath the surface of the sample. The characterization of the evolution of secondary phases, i.e., Laves and carbide, was captured despite the weak diffracted peaks caused by small volume fractions. Thermal history was estimated based on changes in the lattice spacing from the thermal contraction upon cooling. In conclusion, the temporal variation in 2θ with azimuthal direction revealed the evolution in anisotropy of lattice spacing and thus of the mechanical state during laser processing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

From a conventional ferromagnetism to a frustrated magnetism: An unexpected role of Fe in Nd(Al 1-x Fe x ) 2 (x ≤ 0.2)

The structure and magnetic properties of Nd(Al 1-x Fe x ) 2 alloys with x = 0, 0.05, 0.1 and 0.2, which adopt cubic MgCu 2 -type structure with space group Fd3¯m, are studied using x-ray powder diffraction, static and dynamic magnetization, and calorimetric measurements. The lattice constant decreases linearly with increasing Fe content from 8.0106(4) Å to 7.9044(4) Å. Large thermal irreversibilities between zero-field-cooled and field-cooled conditions are observed for all substituted samples. Here, the magnetic transition temperatures exhibit a minimum for x = 0.1, and coercive fields at 2 K increase from 70 Oe for x = 0 to 6.3 kOe for x = 0.2. The absence of λ-type peak in the heat capacity data, frequency dependence of ac magnetic susceptibility, and memory effects indicate formation of a cluster-glass magnetic state when x ≥ 0.1.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A combined experimental and machine learning exploration of Ti 2-x Zr x MnCrFeNi high entropy Laves hydrides

A series of high entropy AB 2 -type Ti 2-x Zr x MnCrFeNi alloys (x = 0.6, 0.7, 0.8, 0.9, 1.0, 1.1 and 1.2) were synthesized to investigate their potential for hydrogen storage and chemical compression. The influence of the Ti/Zr ratio was explored in terms of structural, microstructural and thermodynamic properties. The storage capacity together with the reaction enthalpy and entropy changes of the synthesized high entropy alloys were compared to predictions from Machine Learning (ML) to investigate changes in these properties across the explored composition space. The results revealed that a decreasing Zr content consistently lowered the hydride formation enthalpy and increased the plateau pressure from 8 to >90 bar H 2 at 25 °C, in good agreement with ML predictions. Selected compositions (x = 1.0 and 1.2) demonstrated reversible hydrogen storage capability over 150 cycles, with capacities of 1.34–1.40 wt % H 2 and remarkable reaction kinetics (<4 min) at ambient temperature. These experimental and computational findings highlight the potential of this Laves-HEA system as tuneable, stable, and cost-effective materials suitable for long-term operations in stationary hydrogen storage and compression applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Science and Technology of High Performance Ferritic (HiperFer) Stainless Steels

Future, flexible thermal energy conversion systems require new, demand-optimized high-performance materials. The High performance Ferritic (HiperFer) stainless steels, under development at the Institute of Microstructure and Properties of Materials (IEK-2) at Forschungszentrum Jülich GmbH in Germany, provide a balanced combination of fatigue, creep and corrosion resistance at reasonable price. This paper outlines the scientific background of alloy performance development, which resulted in an age-hardening ferritic, stainless steel grade. Furthermore, technological properties are addressed and the potential concerning application is estimated by benchmarking versus conventional state of the art materials.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Microstructural evolution in the HAZ of Inconel 718 and correlation with the hot ductility test

The nickel-base alloy 718 was evaluated to study the role of preweld heat treatment in reducing or eliminating heat-affected zone hot cracking. Three heat treatments were studied using the Gleeble hot ductility test. A modified hot ductility test was also used to follow the evolution of microstructure during simulated welding thermal cycles. The microstructural evolution was correlated with the hot ductility data in order to evaluate the mechanism of hot cracking in alloy 718. The correlation of hot ductility with microstructure showed that recrystallization, grain growth, and dissolution of precipitates did not in themselves cause any loss of ductility during cooling. Ductility loss during cooling was not initiated until the constitutional liquation of NbC particles was observed in the microstructure. Laves-type phases were found precipitated in the solidified grain boundaries but were not found to correlate with any ductility loss parameter. Mechanisms are reviewed which help to explain how heat treatment controls the hot crack susceptibility of alloy 718 as measured in the hot ductility test.

Thompson, R. G.↗
DOE OSTI2021

Tutorial on Chemical Pressure Analysis: How Atomic Packing Drives Laves/Zintl Intergrowth in K3Au5Tl

The tight atomic packing generally exhibited by alloys and intermetallics can create the impression of their being composed of hard spheres arranged to maximize their density. As such, the atomic size factor has historically been central to explanations of the structural chemistry of these systems. However, the role atomic size plays structurally has traditionally been inferred from empirical considerations. The recently developed DFT-Chemical Pressure (CP) analysis has opened a path to investigating these effects with theory. In this article, we provide a step-by-step tutorial on the DFT-CP method for non-specialists, along with advances in the approach that broaden its applicability. A new version of the CP software package is introduced, which features an interactive system that guides the user in preparing the necessary electronic structure data and generating the CP scheme, with the results being readily visualized with a web browser (and easily incorporated into websites). For demonstration purposes, we investigate the origins of the crystal structure of K3Au5Tl, which represents an intergrowth of Laves and Zintl phase domains. Here, CP analysis reveals that the intergrowth is supported by complementary CP features of NaTl-type KTl and MgCu2-type KAu2 phases. In this way, K3Au5Tl exemplifies how CP effects can drive the merging for geometrical motifs derived from different families of intermetallics through a mechanism referred to as epitaxial stabilization.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Influence of Mo Content on the Precipitation Behavior of 13Ni Maraging Ultra-High Strength Steels

This study offers valuable insights into the precipitation behavior of 13Ni maraging steels, emphasizing the role of molybdenum content in their microstructure, strengthening, and precipitate evolution. Precipitate morphology and crystallography were examined using a combination of high-resolution transmission electron microscopy and selected area electron diffraction. Strengthening mechanisms were assessed through Vickers hardness measurements. All the examined samples exhibited a lath martensite microstructure and displayed an increasing hardness over the aging time. The molybdenum content not only influenced the presence of retained austenite in the initial microstructure but also affected the type of precipitates formed during the early aging stages. Initially, Ni 3 Mo precipitates were formed, succeeded by the formation of more stable Fe 2 (Mo,Ti) Laves precipitates. The ultra-high strength of 13Ni maraging steels arises from the combination of the precipitate type and size distribution. The base composition of 13Ni maraging steels achieved a peak hardness of 798 HV1 through the precipitation of Laves Fe 2 (Mo,Ti) phases ranging from 3 to 14 nm in diameter.

13Ni maraging steels↗
NASA NTRS1994

Microstructure/Oxidation/Microhardness Correlations in Gamma-Based and Tau-Based Al-Ti-Cr Alloys

The relationships between alloy microstructure and air oxidation kinetics and alloy microstructure and microhardness in the Al-Ti-Cr system for exposures at 800 C and 1000 C were investigated. The relevant phases were identified as tau (Ll2), gamma (LIO), r-Al2Ti, TiCrAl (laves), and Cr2AI. Protective alumina formation was associated with tau, Al-rich TiCrAl, and gamma/TiCrAl mixtures. Brittleness was associated with the TiCrAl phase and tau decomposition to A12Ti + Cr2AI. It was concluded that two-phase gamma + TiCrAl alloys offer the greatest potential for oxidation resistance and room temperature ductility in the Al-Ti-Cr system.

Brady, Michael P.↗
NASA NTRS1987

Large-scale volcano-ground ice interactions on Mars

In the present investigation of Martian volcano-ground ice interaction processes, a numerical model is developed that encompasses conductive heat transport, surface radiation, heat transfer to the atmosphere, and H2O phase-changes in an ice-rich permafrost over which lave flows erupt, followed by the intrusion of sills. An examination is made of the two large scale interaction regions formed near Aeolis Mensae and near the volcano Hadriaca Patera, northeast of Hellas. The inferred channel discharges are compared to discharge rates calculated for lava-ground ice interactions, showing that meltwater (probably accumulated under the surface) was rapidly released at a discharge rate that was limited by soil permeability. The volcano-ground ice interactions have been an important Martian geologic process, and could account for the palagonites constituting the Martian dust.

Squyres, Steven W.↗
DOE OSTI2022

Role of Cr Content in Microstructure, Creep, and Oxidation Resistance of Alumina-Forming Austenitic Alloys at 850–900 °C

Creep-rupture properties and oxidation behavior of a series of alumina-forming austenitic (AFA) alloys with variations of Cr contents, based on Fe-(13.5-18)Cr-25Ni-4Al-1.5Nb-0.1C in weight percent, have been evaluated at 850–900 °C. The study investigates material responses in the properties and microstructure through compositional modifications in AFA alloys, targeting performance optimization of alloys under high-temperature, corrosive industrial environments. The creep-rupture life of the alloys at 850 °C and 30MPa monotonically decreased with increasing Cr content, which was correlated with changes in secondary phase volume fractions, such as the reduction in B2-NiAl + Laves-Fe2Nb and increase in Sigma-FeCr with Cr content. The oxidation test at 900 °C in a water-vapor containing environment revealed a range of Cr content from 13.9 to 15.7 wt.%, enabling the formation of stable, protective external alumina scale as well as preventing internal oxidation/nitridation for up to total 7000 h exposure. On the other hand, the alloys with >16.7 wt.% Cr formed Sigma precipitates, which caused a reduction in not only Cr but also Al in the austenite matrix, resulting in less oxidation resistance than other alloys. The findings will guide the further optimization of material performance in the AFA alloy series.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Probing of Local Structure in Laves Compound TbFe 2

Abstract The Laves compounds Tb 1‐x Dy x Fe 2 have attracted much interest due to the giant magnetostriction effect appearing at their morphotropic phase boundary compositions. Although previous studies have established the relationship between the average structure and magnetostrictive properties in these compounds, there is a lack of characterization of their local structures. In this paper, as a first step toward this goal, the evolution of the local structure of the terminal compound (TbFe 2 ) of this system is reported, in an attempt to provide useful information about interatomic bonding in this system. The pair distribution function (PDF) results suggest that the compound presents the rhombohedral local crystal symmetry. The lattice at the local scale shows abnormal thermal expansion which is different from the long scale structure. The different role of the Tb─Fe bond and Fe─Fe bond in affecting the crystal lattice is revealed. These findings highlight the important role of local structure in determining the magnetostrictive properties of the Laves compounds.

Kou, Ronghui↗
DOE OSTI2021

Development of Corrosion- and Erosion-Resistant Coatings for Advanced Ultra-Supercritical Materials

This final report summarized the research efforts and major findings of the Phase I Project “Development of Corrosion- and Erosion-Resistant Coatings for Advanced Ultra-Supercritical Materials”, for the period of October 1, 2019 – Sept. 30, 2021. This project is a collaborative endeavor between Tennessee Tech University, Purdue University, Oak Ridge National Laboratory, Siemens Corporation, and Eastern Plating, LLC, aiming at improving the durability and lifetime of high-pressure (HP) steam turbine blades in advanced ultra-supercritical (A-USC) coal-fired power plants through the development of corrosion/erosion-resistant coatings manufactured via a low-cost electrolytic codeposition process. While Tribaloy alloy T-400C was identified by the U.S. A-USC Materials Consortium as a promising coating composition, further composition optimization is needed to enhance its corrosion and erosion resistance for protecting the A-USC Ni-base turbine components. An integrated computational and experimental approach was employed to optimize coating composition/microstructure and processing parameters. In order to identify candidate coating compositions that could offer balanced properties, thermodynamic calculations were performed to explore the γ+Laves composition space in the Co-Ni-Cr-Mo-Si system with different alloying additions at 600-800 °C. Guided by the calculation results, experimental assessment of selected alloys led to the development of a new generation of Tribaloy compositions with the optimal levels of Cr, Mo and Si, reactive element (e.g., 0.4-0.6 wt.% Y) and other alloying additions. The low-cost and non-line-of-sight electro-codeposition process was employed to deposit a Ni(Co)-CrMoSiY composite coating on commercial Haynes 282 (H282) Ni-base alloy. A diffusion treatment was subsequently applied to convert the composite to the Tribaloy-type coating. Both the codeposition parameters and heat treatment conditions were varied to achieve the desired coating composition, microstructure and phase constituents. In addition, since additive manufacturing (AM) may be an alternative cost-saving option for potential A-USC turbine repair, laser direct deposition was explored to fabricate the H282 alloy with minimal defects. The electro-codeposited Tribaloy coating was also applied to the AM H282 substrate to demonstrate the viability of the coating process in improving the surface finish of AM alloys. Both high-temperature oxidation performance and solid particle erosion (SPE) resistance of model alloys and electro-codeposited coatings were evaluated. About 25 model alloys with various Cr/Mo ratios and reactive element levels, as well as partial substitution of Mo with Nb were evaluated with regard to their oxidation resistance in both air and pure steam at 760-800°C. Compositions based on Ni(Co)-20Cr-18Mo-2.6Si-0.6Y (wt.%) showed significantly improved oxidation resistance over the baseline T400-C. Based on the alloy development results, three generations of new Tribaloy coatings (Gen-1, Gen-2, and Gen-3) with various Mo/Cr contents and Y levels were prepared via electro-codeposition and their microstructure/performance were evaluated. Outstanding air and steam oxidation resistance was achieved for the Gen-2 and Gen-3 coatings. Furthermore, while the SPE resistance of the coatings depended on many factors such as temperature, environment, erodent, velocity and impact angle, the coated samples exhibited similar or better SPE resistance compared to the H282 substrate when magnetite was used as erodent (which is a realistic erodent in A-USC steam turbines). The new Tribaloy coatings also had good long-term compatibility with the H282 alloy substrate. The two large-sized rotating barrels were designed, constructed, and employed to coat dummy HP blades. Uniform coating thickness and microstructure were achieved at various blade locations. Also, a preliminary techno-economic analysis of the proposed coating process was conducted to quantify the cost-effectiveness and to assess the commercial viability of the corrosion- and erosion-resistant coatings. It is estimated that a cost reduction of ~30% could be achieved with the electro-codeposition coating process over the state-of-the-art high velocity oxygen fuel (HVOF) thermal spray. Compared to the leading Tribaloy coating technologies such as HVOF and plasma transfer alloying, electro-codeposition based process has advantages such as low-cost process equipment, uniform deposition even for complex shapes, low levels of contaminants/porosities, reduction of powder waste, and potentially better surface finish and longer turbine service life. The Phase 1 study has demonstrated that it is feasible to develop an electro-codeposited Tribaloy coating with balanced corrosion and erosion properties, even though additional research efforts such as further coating process scale-up and longer-term performance evaluation under realistic A-USC conditions are clearly needed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

IMoFi - Intelligent Model Fidelity: Physics-Based Data-Driven Grid Modeling to Accelerate Accurate PV Integration (Final Report)

This report summarizes the work performed under a project funded by U.S. DOE Solar Energy Technologies Office (SETO) to use grid edge measurements to calibrate distribution system models for improved planning and grid integration of solar PV. Several physics-based data-driven algorithms are developed to identify inaccuracies in models and to bring increased visibility into distribution system planning. This includes phase identification, secondary system topology and parameter estimation, meter-to-transformer pairing, medium-voltage reconfiguration detection, determination of regulator and capacitor settings, PV system detection, PV parameter and setting estimation, PV dynamic models, and improved load modeling. Each of the algorithms is tested using simulation data and demonstrated on real feeders with our utility partners. The final algorithms demonstrate the potential for future planning and operations of the electric power grid to be more automated and data-driven, with more granularity, higher accuracy, and more comprehensive visibility into the system.

14 SOLAR ENERGY↗
DOE OSTI2022

IMoFi (Intelligent Model Fidelity): Physics-Based Data-Driven Grid Modeling to Accelerate Accurate PV Integration Updated Accomplishments

This report summarizes the work performed under a project funded by U.S. DOE Solar Energy Technologies Office (SETO), including some updates from the previous report SAND2022-0215, to use grid edge measurements to calibrate distribution system models for improved planning and grid integration of solar PV. Several physics-based data-driven algorithms are developed to identify inaccuracies in models and to bring increased visibility into distribution system planning. This includes phase identification, secondary system topology and parameter estimation, meter-to-transformer pairing, medium-voltage reconfiguration detection, determination of regulator and capacitor settings, PV system detection, PV parameter and setting estimation, PV dynamic models, and improved load modeling. Each of the algorithms is tested using simulation data and demonstrated on real feeders with our utility partners. The final algorithms demonstrate the potential for future planning and operations of the electric power grid to be more automated and data-driven, with more granularity, higher accuracy, and more comprehensive visibility into the system.

14 SOLAR ENERGY↗
DOE OSTI2022

Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100): Six-Month Progress Update [Slides]

Puerto Rico has committed to meeting its electricity needs with 100% renewable energy by 2050, along with realizing interim goals of 40% by 2025, 60% by 2040, the phase-out of coal-fired generation by 2028, and a 30% improvement in energy efficiency by 2040, as established in Puerto Rico Energy Public Policy Act (Act 17). Since hurricanes Irma and Maria in September 2017, DOE and its national laboratories have provided Puerto Rico energy system stakeholders with tools, training, and modeling support to enable planning and operation of the electric power grid with more resilience against further disruptions. On February 2, 2022, DOE, FEMA, and six national laboratories launched the two-year Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) to conduct comprehensive analysis of stakeholder-driven pathways to Puerto Rico's energy future. The robust and objective energy analysis entails five activities, with an emphasis on power system reliability, resilience, and generation planning. This presentation provides a six-month progress update on the study, including presentation of four initial scenario frameworks defined with extensive stakeholder input.

14 SOLAR ENERGY↗
DOE OSTI2022

Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) (Six-Month Progress Update) [Slides]

Puerto Rico has committed to meeting its electricity needs with 100% renewable energy by 2050, along with realizing interim goals of 40% by 2025, 60% by 2040, the phase-out of coal-fired generation by 2028, and a 30% improvement in energy efficiency by 2040, as established in Puerto Rico Energy Public Policy Act (Act 17). Since hurricanes Irma and Maria in September 2017, DOE and its national laboratories have provided Puerto Rico energy system stakeholders with tools, training, and modeling support to enable planning and operation of the electric power grid with more resilience against further disruptions. On February 2, 2022, DOE, FEMA, and six national laboratories launched the two-year Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) to conduct comprehensive analysis of stakeholder-driven pathways to Puerto Rico's energy future. The robust and objective energy analysis entails five activities, with an emphasis on power system reliability, resilience, and generation planning. This presentation was delivered in a public webinar on July 21, 2022, providing a high level summary of the progress in the first six months of the study, including presentation of four initial scenario definitions based on extensive stakeholder input.

14 SOLAR ENERGY↗